Vapor-permeable, substantially water-impermeable, corrosion-inhibiting composites and methods of making the same

ABSTRACT

Vapor-permeable, substantially water-impermeable, corrosion-inhibiting composites are disclosed herein. For instance, disclosed herein are composites comprising a first layer comprising a first nonwoven; and a second layer adjacent to and mechanically integrated with the first layer, the second layer comprising a polymer having a melt flow index of about 10 g/10 mins to about 200 g/10 mins, and a corrosion inhibitor, wherein the composite has a moisture vapor transmission rate of from about 25 g/m 2 /day to about 1000 g/m 2 /day when measured at about 23° C. and about 50% relative humidity. Also disclosed herein are methods of making and using the same.

CROSS-REFERENCE TO RELATED APPLICATIONS

This patent application claims the priority benefit of U.S. ProvisionalApplication No. 62/112,878 filed on Feb. 6, 2015, the contents of whichare incorporated herein by reference.

TECHNICAL FIELD

This disclosure relates to vapor-permeable, substantiallywater-impermeable, corrosion-inhibiting composites, as well as relatedproducts and methods.

BACKGROUND

Composites that are breathable (i.e., vapor-permeable and substantiallywater-impermeable) have been prepared for multiple applications. Thesecomposites have been heretofore prepared by laminating various plasticlayers together using adhesives. However, improved methods for makingbreathable, corrosion-inhibiting composites are desired.

SUMMARY

Disclosed herein are composites that are vapor-permeable, substantiallywater-impermeable, and corrosion inhibiting. The composites comprise afirst layer comprising a first nonwoven, and a second layer comprising apolymer and a corrosion inhibitor. The first layer is adjacent to andmechanically integrated with a second layer. in some embodiments of theinvention, the first layer is melt bonded to the second layer. In someembodiments of the invention, the composite can have a moisture vaportransmission rate (MVTR) of from about 25 g/m²/day to about 1000g/m²/day (e.g., about 50 g/m²/day to about 500 g/m²/day) when measuredat about 23° C. and about 50% relative humidity.

In some embodiments of the invention, the polymer in the second layercomprises a polymer (e.g., a polyolefin such as low-density polyethyleneor propylene-ethylene copolymer). The polymer can have a melt flow indexof about 10 g/10 mins to about 300 g/10 mins (e.g., about 20 g/10 minsto about 200 g/10 mins). The second layer of the composite can have afilm weight of from about 15 g/m² to about 200 g/m². In someembodiments, the polymer is present in the second layer in an amount ofat least about 50% to about 99%, by weight of the second layer. In someembodiments of the invention, the second layer comprises an additionalpolymer that does not have a melt flow index of about 10 g/10 min toabout 300 g/10 min.

The second layer also comprises a corrosion inhibitor e.g., morpholineaccording to an embodiment of the invention. The second layer mayfurther comprise a carrier e.g., silica according to an embodiment ofthe invention for the corrosion inhibitor. The corrosion inhibitor canbe present in an amount of about 0.5% to about 5%, by weight of thesecond layer.

In some embodiments of the invention, the composite further comprises athird layer adjacent to and mechanically integrated with the secondlayer, wherein the third layer comprises a second nonwoven. In someembodiments of the invention, the third layer is melt bonded to thesecond layer. The composite can be substantially free of an adhesive incertain embodiments of the invention. For example, in some embodimentsof the invention, the composite does not comprise an adhesive layerbonding the first layer to the second later or second layer to the thirdlayer.

One or more of the first nonwoven and the second nonwoven of theinvention may include a spunbond layer. According to some exemplaryembodiments of the invention , the first nonwoven and/or the secondnonwoven may comprise a polyester, a polyolefin (e.g., polypropylene, apolyethylene, or a mixture thereof), or a mixture thereof. The firstnonwoven and/or the second nonwoven can have a basis weight of from ofabout 15 g/m² to about 120 g/m². In some embodiments, a surface of oneor more of the first nonwoven and second nonwoven, independently,includes a hydrophilic coating and/or a hydrophobic coating.

The composite can have a variety of properties, including but notlimited to being vapor-permeable, substantially water-impermeable,corrosion-inhibiting, drapable, ultraviolet (UV) resistant, or a mixturethereof. The composite of can have a hydrostatic head of from about 20cm to about 200 cm.

The composite disclosed herein can be used a as a protective cover(e.g., a grill cover, a gun cover, an outdoor furniture cover, a vehiclecover).

Also disclosed herein are methods of producing the composites disclosedherein. The method can include extruding a corrosion-inhibiting mixturecomprising a polymer having a melt flow index of about 10 g/10 mins toabout 200 g/10 mins and a corrosion inhibitor onto a surface of a firstnonwoven at an extrusion temperature of from about 170° C. to about 320°C. to form a film layer on the first nonwoven. The method can furtherinclude mixing the polymer with a corrosion inhibitor to produce thecorrosion-inhibiting mixture. The method can further comprise the stepof applying a second nonwoven to the film layer on the first nonwoven,which can occur while the film layer is molten.

The details of one or more embodiments of the invention are set forth inthe description below. Other features, objects, and advantages will beapparent from the description and drawings, and from the claims.

BRIEF DESCRIPTION OF THE FIGURES

FIG. 1 depicts a cross-section of one embodiment of the invention of acomposite disclosed herein;

FIG. 2 depicts one embodiment of the invention of an apparatus forextruding a corrosion-inhibiting mixture onto a nonwoven;

FIG. 3 depicts one embodiment of the invention of an apparatus forring-rolling a composite disclosed herein;

FIG. 4 shows results of a corrosion inhibition of Sample A conducted onthree panels as described in Example 3;

FIG. 5 shows results of a corrosion inhibition of Sample B conducted onthree panels as described in Example 3;

FIG. 6 shows results of a corrosion inhibition of Sample C conducted onthree panels as described in Example 3;

FIG. 7 shows results of a corrosion inhibition of Sample I conducted onthree panels as described in Example 5;

FIG. 8 shows results of a corrosion inhibition of Sample J conducted onthree panels as described in Example 6;

FIG. 9 shows results of a corrosion inhibition of Sample L conducted onthree panels as described in Example 8;

FIG. 10 shows results of a corrosion inhibition of Sample M conducted onthree panels as described in Example 8;

FIG. 11 shows results of a corrosion inhibition of control panels asdescribed in Example 10, after 144 hours;

FIG. 12 shows results of a corrosion inhibition of Sample O panels asdescribed in Example 10, after 144 hours;

FIG. 13 shows results of a corrosion inhibition of a control panels asdescribed in Example 10, after 288 hours;

FIG. 14 shows results of a corrosion inhibition of Sample O panels asdescribed in Example 10, after 288 hours;

FIG. 15 shows results of a corrosion inhibition of a control panels asdescribed in Example 10, after 576 hours;

FIG. 16 shows results of a corrosion inhibition of Sample O panels asdescribed in Example 10, after 576 hours;

FIG. 17 shows the condition of the control fabric for three samples asdescribed in Example 10, after 576 hours; and

FIG. 18 shows the condition of the Sample O fabric for three samples asdescribed in Example 10, after 576 hours.

DETAILED DESCRIPTION

Disclosed herein are composites that are vapor permeable, substantiallywater impermeable, and corrosion inhibiting. As depicted in FIG. 1, thecomposite 100 can comprise a first layer 110 comprising a first nonwovenadjacent to a second layer 112 comprising a polymer and a corrosioninhibitor. The second layer 112 can be mechanically integrated with thefirst layer, for example, through melt bonding. The second layer 112 cancomprise a polymer and a corrosion inhibitor. In some embodiments of theinvention, the composite 100 further comprises an optional third layer114 adjacent to and mechanically integrated with the second layer 112,wherein the third layer 114 comprises a second nonwoven fabric. Thecomposite 100 can further comprise an optional coating 116 on a surfaceof the first layer 110 and/or an optional coating 118 on the third layer114.

First Layer comprising a First Nonwoven

The composites disclosed herein comprise a first layer comprising afirst nonwoven. The first nonwoven can be formed from any suitablefibrous material that is compatible with the second layer comprising apolymer. For instance, the first nonwoven can be formed from anymaterial capable of becoming mechanically integrated with the secondlayer. As used herein, the term “nonwoven” refers to a substratecontaining one or more layers of fibers that are bonded together, butnot in an identifiable manner as in a knitted or woven material.

The first nonwoven can be formed from any suitable polymer. In someembodiments of the invention, the polymer may include a polyolefin, apolyester, or a combination thereof As used here, the term “polyolefin”refers to a homopolymer or a copolymer made from a linear or branched,cyclic or acyclic alkene. In some embodiments of the invention, thepolyolefin can include polyethylene, polypropylene, polybutylene, acopolymer of ethylene, propylene and/or butylene, or a mixture thereof.

In some embodiments of the invention, the first nonwoven comprises apolyethylene, In some embodiments of the invention, the polyethyleneincludes low-density polyethylene (e.g., having a density from about0.910 g/cm² to about 0.925 g/cm ²), linear low-density polyethylene(e.g., having a density from about 0.910 g/cm² to about 0.935 g/cm ²),or high-density polyethylene (e.g., having a density from about 0.935g/cm² to about 0.970 g/cm²). High-density polyethylene can be producedby copolymerizing ethylene with one or more C₄ to C₂₀ α-olefins.Examples of suitable α-olefins include 1-butene, 1-pentene,4-methyl-1-pentene, 1-hexene, 1-octene, 1-decene, and combinationsthereof. The high-density polyethylene can include up to about 20 molepercent of the above-mentioned α-olefin comonomers.

The first nonwoven can, in some embodiments of the invention, comprise apolyester. The polyester can include polyethylene terephthalate (PET),polybutylene terephthalate (PBT), polytrimethylene terephthalate (PIT),polyethylene naphthalate (PEN), polyglycolide or polyglycolic acid(PGA), potylactide or polylactic acid (PIA), polycaprolactone (PCL),polyethylene adipate (PEA), polyhydroxyalkanoate (PHA), or mixturesthereof.

In some embodiments of the invention, the first nonwoven comprisespolypropylene. In some embodiments of the invention, the first nonwovencomprises polypropylene and one or more of the polyethylene polymersdescribed above, wherein the polypropylene can be blended with one ormore polyethylene polymers.

The first nonwoven can be formed from single component fibers, i.e.,fibers containing a polymer having a single chemical structure (e.g., apolymer described in the preceding paragraph such as a polyethylene, apolypropylene, or a polyethylene terephthalate). In some embodiments ofthe invention, the first nonwoven can include single component fibersmade from polymers having the same chemical structure but differentcharacteristics (e.g., molecular weights, molecular weightdistributions, density, or intrinsic viscosities). For example, thefirst nonwoven can include a mixture of a low-density polyethylene and ahigh-density polyethylene according to certain embodiments of theinvention . Such fibers are still referred to as a single componentfiber in this disclosure.

According to an embodiment of the invention, the first nonwoven may alsobe formed from multicomponent fibers, i.e., fibers containing polymerswith different chemical structures (such as two different polymersdescribed above). For example, the first nonwoven can be formed from amixture of a polypropylene and a polyethylene terephthalate. In someembodiments of the invention, a multicomponent fiber can have asheath-core configuration (e.g., having a polyethylene terephthalate asthe core and a polypropylene as the sheath). In some embodiments of theinvention, a multicomponent fiber may include two or more polymerdomains in a different configuration (e.g., a side-by-sideconfiguration, a pie configuration, or an “islands-in-the-sea”configuration).

The first nonwoven can be made by any method known in the art, such as aspunlacing, spunbonding meltblowing, carding, air-through bonding, orcalendar bonding process. In some embodiments of the invention, thefirst nonwoven comprises a spunbond layer. In some embodiments, thespunbond layer comprises a plurality of continuous fibers, at least some(e.g., all) of which are bonded. The term “continuous fiber” mentionedherein refers to a fiber formed in a continuous process that is notshortened before it is incorporated into a nonwoven substrate containingthe continuous fiber.

The spunbond layer may be manufactured according to the followingprocess, for instance. After the polymer for making single componentfibers is melted, the molten polymer can be extruded from an extrudingdevice. The molten polymer can then be directed into a spinneret withcomposite spinning orifices and spun through this spinneret to formcontinuous fibers. The fibers can subsequently be quenched (e.g., bycool air), attenuated mechanically or pneumatically (e.g., by a highvelocity fluid), and collected in a random arrangement on a surface of acollector (e.g., a moving substrate such as a moving wire or belt) toform a nonwoven web. In some embodiments, a plurality of spinnerets withdifferent quenching and attenuating capability can be used to place oneor more (e.g., two, three, four, or five) layers of fibers on acollector to form a spunbond substrate containing one or more layers ofspunbonded fibers (e.g., an S, SS, or SSS type of substrate). In someembodiments of the invention, the first nonwoven comprises a spunbondpolypropylene layer. In some embodiments, the nonwoven comprises ameltblown layer. For example, one or more layers of meltblown fibers maybe inserted between the layers of the above-described spunbonded fibersto form a substrate containing both spunbonded and meltblown fibers SMS,SMMS, or SSMMS type of substrate).

A plurality of intermittent bonds may be formed between at least some ofthe fibers (e.g., all of the fibers) randomly disposed on the collectorto form a unitary, coherent, nonwoven substrate according to certainembodiments of the invention. Intermittent bonds can be formed by asuitable method such as mechanical needling, thermal bonding, ultrasonicbonding, chemical bonding, or a combination thereof. Bonds can becovalent bonds (e.g., formed by chemical bonding), physical attachments(e.g., formed by thermal bonding), or a combination thereof. In someembodiments, intermittent bonds are formed by thermal bonding. Forexample, bonds can be formed by known thermal bonding techniques, suchas point bonding (e.g., using calender rolls with a point bondingpattern) or area bonding (e.g., using smooth calender rolls without anypattern). In some embodiments, the fibers are area bonded or pointbonded with each other through a plurality of intermittent bonds.

According to an embodiment of the invention, the first layer may have abasis weight of from of about 15 g/m² to about 120 g/m² as measured byASIM D3776 (1996). In some embodiments, the first layer has a basisweight of about 15 g/m² or greater (e.g., about 20 g/m² or greater,about 25 g/m ² or greater, about 30 g/m² or greater, about 35 g/m² orgreater, about 40 g/m² or greater, about 45 g/m² or greater, about 50g/m² or greater, about 55 g/m² about 60 g/m² or greater, about 70 g/m²or greater, about 80 g/m² or greater, about 90 g/m² greater, or about100 g/m² or greater). In some embodiments of the invention, the firstlayer has a basis weight of from about 120 g/m² or less (e.g., about 110g/m² or less, about 100 g/m² or less, about 90 g/m² or less, about 80g/m² or less, about 70 g/m² or less, about 65 g/m² or less, about 60g/m² or less, about 55 g/m² or less, about 50 g/m² or less, about 45g/m² m or less, about 40 g/m² or less, about 35 g/m² or less, about 30g/m² or less, about 25 g/m² m or less, or about 20 g/m² or less). Insome embodiments, the first layer has a basis weight of from about 15g/m² to about 120 g/m² (e.g., from about 20 g/m² to about 90 g/m², orfrom m about 25 g/m² to about 60 g/m².

Second Layer

In an embodiment of the invention, the composite comprises a secondlayer adjacent to and mechanically integrated with the first layer, thesecond layer comprising a polymer and a corrosion inhibitor. The polymercan be any polymer that can be extruded at a low temperature (e.g.,about 400° C. or below) to minimize degradation of the corrosioninhibitor while still being capable of producing a breathable film. Thepolymer, in some embodiments of the invention, is not consideredbreathable on its own. In some embodiments, the polymer includes apolyolefin. The polyolefin can include any polyolefin described above asa polymer for use in the first nonwoven. In some embodiments, thepolymer includes LDPE.

In sonic embodiments of the invention, the second layer can comprise anelastomer. The elastomer can be used alone or in combination with apolyolefin described above. Examples of suitable elastomers includevulcanized natural rubber, ethylene alpha olefin rubber (EPM), ethylenealpha olefin diene monomer rubber (EPDM), styrene-isoprene-styrene (SIS)copolymers, styrene-butadiene-styrene (SBS) copolymers,styrene-ethylene-butylene-styrene (SEBS) copolymers, ethylene-propylene(EP) copolymers, ethylene-vinyl acetate (EVA) copolymers,ethylene-maleic anhydride (EMA) copolymers, ethylene-acrylic acid (EEA)copolymers, and butyl rubber. A commercial example of such an elastomeris VERSIFY (i.e., an ethylene-propylene copolymer) available from Dow(Midland, Michigan). Without wishing to be bound by theory, it isbelieved that one advantage of using an elastomer in the second layer isthat the composite containing such a film can have both improved tensilestrength (e.g., by at least about 5% or at least about 10%) and improvedelongation es., by at least about 20% or at least about 50%).

In some embodiments of the invention, the second layer further includesa functionalized polyolefin (es., functionalized polyethylene orpolypropylene), such as a functionalized polyolefin graft copolymers.Examples of such polyolefin graft copolymers include, but are notlimited to, polypropylene-g-maleic anhydride and polymers formed byreacting PP-g-MAH with a polyetheramine. In some embodiments of theinvention, such a functionalized polyolefin can be used with acompatibilizer to minimize the phase separation between the componentsthe second layer or improve mechanical integration between the first andsecond layers (and/or between second layer and optional third layer).The compatibilizer may be from about 0.1% to about 30% (e.g., about 0.5%to about 15%, or about 1% to about 5%) of the total weight the secondlayer according to certain embodiments of the invention.

A commercially available polymer that can be used in the second layerincludes, but is not limited to, VISTAMAXX™ 6202FL by EXXON, apropylene-based elastomer, VISTAMAXX™ 6202FL can be processed attemperatures of 400° C. or below, which, without intending to be boundby the theory, reduces thermal degradation of the corrosion inhibitor.VISTAMAXX™ 6202FL is also compatible with, for instance, a nonwovencomprising polypropylene because it can mechanically integrate withpolypropylene nonwovens, even at the low extrusion temperaturesdescribed herein.

The polymer may have any melt flow index that allows the polymer to befluid enough for extrusion at the extrusion temperatures describedherein. In some embodiments, the polymer can have a melt flow index ofabout 10 g/10 mins to about 300 g/10 mins as measured by ASTM D1238-13.In some embodiments, the polymer has a melt flow index of about 10 g/10mins or greater (e.g., about 15 g/10 mins or greater, about 20 g/10 minsor greater, about 25 g/10 mins or greater, about 30 g/10 mins orgreater, about 40 g/10 mins or greater, about 60 g/10 mins or greater,about 80 g/10 mins or greater, about 100 g/10 mins or greater, about 120g/10 mins or greater, about 140 g/10 mins or greater, about 160 g/10mins or greater, about 180 g/10 mins or greater, about 200 g/10 mins orgreater, or about 250 g/10 mins or greater). In some embodiments of theinvention, the polymer has a melt flow index of about 300 g/10 mins orless (e.g., about 250 g/10 mins or less, about 200 g/10 mins or less,about 180 g/10 mins or less, about 160 g/10 mins or less, about 140 g/10mins or less, about 120 g)10 mins or less, about 100 g/10 mins or less,about 80 g/10 mins or less, about 60 g/10 mins or less, about 40 g/10mins or less, about 30 g/10 mins or less, about 25 g/10 mins or less, orabout 20 g/10 mins or less). In some embodiments, the polymer has a meltflow index of from about 10 g/10 mins to about 300 g/10 mins es., fromabout 20 g/10 mins to about 250 g/10 mins, from about 30 g/10 mins toabout 200 g/10 mins, from about 40 g/10 mins to about 100 g/10 mins).

In some embodiments of the invention, in addition to a first polymerhaving the above-referenced melt flow index, the second layer can have asecond polymer. The amount of the first polymer may be at least 50% byweight of the second layer according to certain embodiments of theinvention. For example, the first polymer may be present in the secondlayer in an amount of from about 50% to about 99%, by weight of thesecond layer. In some embodiments of the invention, the first polymer ispresent in the second layer in an amount of about 50% or greater e.g.,about 60% or greater, about 70% or greater, about 80% or greater, about90% or greater, or about 95% or greater), by weight. In some embodimentsof the invention, the first polymer is present in the second layer in anamount of about 99% or less (e.g., about 95% or less, about 90% or less,about 80% or less, about 70% or less, or about 60% or less), by weight.

The second layer may also comprise a corrosion inhibitor, according tocertain embodiments of the invention. The corrosion inhibitor maycomprise any compound that can enhance the corrosion inhibiting abilityof the composite. The corrosion inhibitor may be a volatile corrosioninhibitor (WI). VCIs are volatile compounds that can emit ions thatcondense on metallic surfaces to form a mono-molecular layer thatinteracts with corrosion agents to protect the surface, VCIs may becontinuously self-replenishing and environmentally benign. Examples ofcorrosion inhibitors include, but are not limited to, amine salts,nitrates of amine salts, benzoates of amine salts, triazole derivatives,alkali dibasic acid salts, alkali nitrites, tall oil imidazolines,alkali metal molybdates, or a combination thereof. In some embodiments,the corrosion inhibitor comprises ammonium benzoate, sodium molybdate,sodium nitrite, sodium erythorbate, benzotriazole, disodium sebacate,dicyclohexylammonium nitrite, potassium pyrophosphate; sodium benzoate,or a combination thereof. In some embodiments of the invention, thecorrosion inhibitor comprises morpholine.

The second layer may further comprise a carrier for the corrosioninhibitor according to an embodiment of the invention. The carrier maybe a porous material capable of remaining substantially nonvolatile atthe processing temperatures described herein. In some embodiments, thecarrier also acts as a desiccant. The carrier may be an inorganiccarrier such as talc, silica, a clay such as kaolin, a solid flameretardant, diatomaceous earth, magnesium carbonate, barium carbonate,magnesium sulfate, calcium sulfate, aluminum hydroxide, zinc oxide,magnesium hydroxide, calcium oxide, magnesium oxide, alumina, mica,glass powder, ferrous hydroxide, zeolite, barium sulfate; or othermineral fillers, or mixtures thereof. In some embodiments, the carriercomprises acetyl salicylic acid, an ion exchange resin, wood pulp, pulppowder, borox, an alkaline earth metal, or a mixture thereof. In someembodiments, the carrier is silica. In some embodiments, the corrosioninhibitor is encapsulated in the carrier.

The corrosion inhibitor can be provided in the second layer in anyamount sufficient o inhibit corrosion for the desired application. Insome embodiments of the invention, the corrosion inhibitor is providedin the second layer in an amount to maximize corrosion inhibition in thedesired application. In some embodiments of the invention, the corrosioninhibitor in the second layer is provided in an amount to minimize thetoxicity of the corrosion inhibiting compound while maintaining thecorrosion inhibiting properties for the desired application. In someembodiments of the invention, the corrosion inhibitor is present in thesecond layer in an amount of about 0.5% or greater (e.g., about 1% orgreater, about 1.5% or greater, about 2% or greater, about 2,5% orgreater, or about 3% or greater), by weight of the second layer. In someembodiments, the corrosion inhibitor is present in the second layer inan amount of about 5% or less (e.g., about 4.5% or less, about 4% orless, about 3,5% or less, about 3% or less, about 2,5% or less, about 2%or less, about 1.5% or less, or about 1% or less), by weight of thesecond layer. In some embodiments, the corrosion inhibitor is present inthe second layer in an amount of from about 0.5% to about 3% (e.g., fromabout 0.75% to about 2.5%, or from about 1% to about 2%), by weight ofthe second layer. Without wishing to be bound to theory, it is believedthat the corrosion inhibitor can bloom or migrate to a surface of thesecond layer as the second layer is heated (e.g., during extrusion),though the extrusion temperature can be selected to ensure that thecorrosion inhibitor does not leave the second layer. Thus, in someembodiments of the invention, the second layer can have a concentrationgradient whereby more of the corrosion inhibitor is present at an outersurface of the second layer. that at the center of the second layer. Insome embodiments of the invention, the corrosion inhibitor may also hepresent in the first layer.

In some embodiments of the invention, the corrosion inhibitor is presentin a masterbatch containing the polymer, the carrier, and the corrosioninhibitor. The corrosion inhibitor can be compounded into the same basepolymer (e.g., VISTAMAXX™ 6202H,), which by itself can give waterbarrier properties and which can adhere two nonwoven layers together.The combination of the polymer and corrosion inhibitor can impartcorrosion protection and breathability to the composite. An example of acommercially available corrosion inhibitor masterbatch is SAM81720® (bySTANDRIGE COLOR CORPORATION). SAM81720® contains 15% of CHEMSTAT®CI-1020 from PCC CHEMAX and 85% virgin VISTAMAXX™ 6202FL. CHEMSTAT®CI-1020 contains 60% antistat mixture and 40% synthetic amorphous silicadioxide hydrate. CHEMSTAT® CI-1020 also comprises ethoxylated tallowamine, diethanolamine, and less than 3% morpholine.

Third Layer

In some embodiments of the invention, the composite further may comprisea third layer adjacent to and mechanically integrated with the secondlayer, wherein the third layer comprises a second nonwoven. The secondnonwoven may, independently, comprise any material discussed above withrespect to the first nonwoven. For instance, the first nonwoven may be apolypropylene and the second nonwoven may be a polyethylene.

The second nonwoven may, independently, be of any basis weight describedabove for the first nonwoven. In some embodiments of the invention, thethird layer is oriented in use to face a corrodible object in need ofprotection from, for instance, the environment. In some embodiments ofthe invention, the third layer has a lower basis weight than the firstlayer such that the second layer (with the corrosion inhibitor) can becloser to the corrodible object. For example, in some embodiments of theinvention, the first layer can have a basis weight of 60 g/m² and thethird layer can have a basis weight of 25 g/m².

Additives

In some embodiments of the invention, an effective amount of variousadditives can be incorporated into the first layer, the second layer,the third layer, or a combination thereof. Suitable additives includepigments, antistatic agents, antioxidants, ultraviolet lightstabilizers, antiblocking agents, lubricants, processing aids, waxes,coupling agents for fillers, softening agents, thermal stabilizers,tackifiers, polymeric modifiers. hydrophobic compounds, hydrophiliccompounds, anticorrosive agents, and mixtures thereof. In certainembodiments, additives such as polysiloxane fluids and fatty acid amidescan be included to improve processability characteristics.

Pigments or dyes of various colors may be added to provide the resultantcomposite that is substantially opaque and exhibits uniform color. Forexample, the composite can have a sufficient amount of pigments or dyesto produce an opacity of at least about 85% (e.g., at least about 90%,at least about 95%, at least about 98%, or at least about 99%). Suitablepigments and dyes include, but are not limited to, antimony trioxide,azurite, barium borate, barium sulfate, cadmium pigments e.g., cadmiumsulfide . calcium chromate, calcium carbonate, carbon black,chromium(III) oxide, cobalt pigments (e.g., cobalt(II) aluminate), leadtetroxide, leadcte chromate, lithopone, orpiment, titanium dioxide, zincoxide and zinc phosphate. Preferably, the pigment or dye includestitanium dioxide, carbon black, or calcium carbonate. The pigment or dyecan be about 1 percent to about 20 percent (e.g., about 3 percent toabout 10 percent) of the total weight of the first layer, the secondlayer, and/or the third layer.

In some embodiments of the invention, certain additives can be used tofacilitate manufacture of the composite. For example, antistatic agentsmay be incorporated into the first layer, the second layer, and/or thethird layer to facilitate processing of these materials. In addition,certain additives may be incorporated in the composite for specific endapplications.

The first layer, second layer, and/or third layer may also include afiller, according to certain embodiments of the invention. The fillermaterial may, for example, include any material described above ascarriers for the corrosion inhibitor. The filler may be added in anamount of up to about 60 weight percent (e.g., from about 2 to about 50,from about 5 to about 40 or about 10 to about 30 weight percent) of thefirst layer the second layer, and/or the third layer.

Surface Treatments

In some embodiments of the invention, a surface of one or more of thefirst nonwoven and second nonwoven can include a coating such as ahydrophilic or a hydrophobic coating. ho some embodiments of theinvention, a surface of the first nonwoven includes a hydrophobiccoating and a surface of the second nonwoven includes a hydrophiliccoating, In some embodiments of the invention, only one of the firstlayer or third layer comprises a coating. In some embodiments of theinvention, both the first layer and third layer comprise a coating, andthe coating may be different according to certain embodiments or thecoating may the same in certain other embodiments, The hydrophiliccoating can include a surfactant to improve the hydrophilicity of thenonwoven and suitable surfactants include nonionic and anionicsurfactants such as dioctyl sodium sulfosuccinate, sodiumalkylaryipolyethersulfonate, and phospholipids. The hydrophobic coatingcan be applied to increase the barrier properties of the nonwoven andcan include, for example, a silicone polymer. As shown in FIG. 1, thecoating 116 or 118 on the nonwoven 112 or 114 is typically providedopposite the film layer 118.

The Composite

FIG. 1 depicts an exemplary embodiment of the invention showing thecomposite 100 comprising a first layer 110 having a first nonwovenadjacent to and mechanically integrated with a second layer 112 having apolymer and a corrosion inhibitor. In some embodiments of the invention,the composite 100 comprises a first layer 110 comprising a firstnonwoven, and a second layer 112 adjacent to and mechanically integratedwith the first layer, the second layer comprising a polymer and acorrosion inhibitor. In some embodiments, the composite 100 furthercomprises an optional third layer 114 adjacent to and mechanicallyintegrated with the second layer 112, wherein the third layer 114comprises a second nonwoven. The composite 100 can further comprise anoptional coating 116 on a surface of the first layer 110 and/or anoptional coating 118 on the third layer 114.

In some embodiments of the invention, the composite is substantiallyfree of adhesives (wherein the second layer is not considered anadhesive in this sense). In some embodiments of the invention, thecomposite does not comprise an additional adhesive layer bonding thefirst layer to the second layer, In sonic embodiments of the invention,the composite does not comprise an additional adhesive layer bonding thesecond layer to the third layer. For instance, the first nonwoven andthe second nonwoven can be melt bonded to the film layer. According toexemplary embodiments of the invention, the film layer may be extrusionlaminated to the first nonwoven and the second nonwoven may be appliedto the film layer while it is molten (or at least tacky) to produce thecomposite.

Method of Making the Composite

Also disclosed herein are methods of producing the composites disclosedherein. The method may include mixing a polymer with a corrosioninhibitor to produce a corrosion-inhibiting mixture, and extruding thecorrosion-inhibiting mixture onto a surface of a first nonwoven to forma film layer on the first nonwoven. Without intending to be bound by thetheory, higher extrusion temperatures may make these films morebreathable, since higher extrusion temperatures cause off-gassing, whichcreates more pores and thus greater breathability. However, greaterbreathability may come at the expense of lower corrosion-inhibitingeffectiveness, since the higher temperature may cause greaterdegradation of the corrosion inhibitor or cause the corrosion inhibitorto migrate out (i.e., flash off) of the composite, Accordingly, theinventor has discovered that the extrusion temperature should be lowenough to avoid degrading the corrosion inhibitor. In some embodiments,the corrosion-inhibiting mixture is extruded onto the first nonwoven atan extrusion temperature of from about 170° C. to about 320° C. (e.g.,from about 180° C. to about 280° C. or from about 185° C. to about 250°C.). The corrosion-inhibiting mixture can be extruded directly onto oneor more nonwoven layers, allowing the corrosion-inhibiting mixture tomechanically wrap around the fibers of the one or more nonwoven layerssuch that the polymer layer is mechanically integrated with the one ormore nonwoven layers in the finished composite. The method may furthercomprise adding a second nonwoven to the film layer of the firstnonwoven, according to an embodiment of the invention. In someembodiments of the invention, the second nonwoven is added to the filmlayer while the film layer is still molten.

FIG. 2 is a scheme illustrating an exemplary process for making acomposite described using an extruder 200. As shown in FIG. 2, acorrosion-inhibiting mixture (comprising a polymer having a melt flowindex of about 10 g/10 mins to about 200 g/10 mins and a corrosioninhibitor) can be fed into an inlet 210 of an extruder hopper 212. Forexample, masterbatch pellets including the polymer and the corrosioninhibitor and additional polymer pellets can be added via the extruderhopper 212. The composition can then be melted and mixed in a screwextruder 214. The molten mixture can be discharged from extruder 214under pressure through a heated line 216 to a flat film die 218.Extrusion melt 220 discharging from the flat film die 218 can be coatedon the first nonwoven from a roll 222. The coated substrate can thenenter a nip formed between rolls 224 and 226, which can be maintained ata suitable temperature (e.g., from about 10° C. to about 120° C.).Passing the coated substrate through the nip formed between the cooledrolls 224 and 226 can quench the extrusion melt 220 while at the sametime compressing the extrusion melt 220 so that it contacts and becomesmechanically integrated with the first nonwoven. In some embodiments ofthe invention, the roll 224 can be a smooth rubber roller with alow-stick surface coating while the roll 226 can be a metal roll. Atextured embossing roll can be used to replace the metal roll 226 if acomposite with a textured film layer is desired. When the extrusion melt220 is cooled on the first nonwoven, it forms a composite having acorrosion-inhibiting mixture adjacent to and mechanically integratedwith a first nonwoven. The composite thus formed can then be collectedon a collection roll 228. In some embodiments of the invention, thesurface of the nonwoven can be corona or plasma treated before it iscoated with the extrusion melt 220 to improve the mechanical integrationbetween the nonwoven and the corrosion-inhibiting mixture.

The composite formed above can then be stretched (e.g., incrementallystretched or locally stretched). Without wishing to be bound by theory,it is believed that stretching the composite can generate pores in thefilm layer that can enhance water vapor transmission. However, in someembodiments of the invention, the composite is not stretched, and iswater-vapor permeable and substantially water-impermeable withoutstretching. The composite can be stretched (e.g., incrementallystretched) in the machine direction (MD) or the cross-machine direction(CD) or both (biaxially) either simultaneously or sequentially. As usedherein, “machine direction” refers to the direction of movement of anonwoven material during its production or processing. For example, thelength of a nonwoven material can be the dimension in the machinedirection. As used herein, “cross-machine direction” refers to thedirection that is essentially perpendicular to the machine directiondefined above. For example, the width of a nonwoven material can be thedimension in the cross-machine direction, Exemplary stretching methodsinclude ring rolling (in the machine direction and/or the cross-machinedirection), tentering, embossing, creping, and button-breaking.

In some embodiments of the invention, the composite can be stretched atan elevated temperature. The elevated temperature can be from about 50°C. to about 100° C. Stretching the composite at an elevated temperaturecan increase the MVTR by increasing the number of the pores, rather thanthe size of the pores (which can reduce the hydrostatic head (i.e.,resistance of water) of the composite). As a result, it is believed thatstretching the composite described above at an elevated temperature canimprove the MVTR of the resultant composite while still maintaining anappropriate hydrostatic head of the composite.

FIG. 3 illustrates an exemplary ring-rolling apparatus 300 used toincrementally stretch the composite described above in the cross-machinedirection. The apparatus 300 includes a pair of grooved rolls 310, eachincluding a plurality of grooves 312. The grooves 312 stretch thecomposite described above. In some embodiments of the invention, one orboth of the rolls 310 can he heated to an elevated temperature e.g.,from about 50° C. to about 100° C.) by passing a hot liquid throughrolls 310. The composite described above can also be incrementallystretched in the machine direction. It is contemplated that thecomposite can also be incrementally stretched using variations of thering-rolling apparatus 300 and/or one or more other stretching apparatusknown in the art.

In some embodiments of the invention, the composite described above canbe e bossed before or after being stretched (e.g., by using acalendering process). For example, the composite can be embossed bypassing it through a pair of calender rolls in which one roll has anembossed surface and the other roll has a smooth surface. Embossing mayincrease the surface area, which can facilitate vapor transmissionthrough the composite. In some embodiments of the invention, at leastone (e.g., both) of the calender rolls is heated, e.g., by circulating ahot fluid through the roll. In some embodiments of the invention, thecomposite is not embossed, and is vapor-permeable and substantiallywater-impermeable without embossing.

Uses for the Composite

The composites disclosed herein may be used in a variety ofapplications. For example, the composites disclosed herein can be usedin any applications where providing corrosion protection to metalsurfaces is beneficial. The composites can be used as indoor or outdoorprotective covers. The composites may be used in, for instance,shipping, packing, and storing applications.

For instance, the composites disclosed herein may be used in coveringsfor furniture (e.g., seating such as chairs, umbrellas, tables,accessories), grills, vehicles (e.g., cars, trucks, vans, sports utilityvehicles (SUVs), boats, recreation vehicles (RVs), all-terrain vehicles(ATVs), motorcycles, tractors, snowmobiles, utility vehicles forconstructions sites, airplanes, helicopters, etc.), bicycles, or otherobjects exposed to outdoor elements. In some embodiments of theinvention, the composite is used in an artillery covering (e.g., a guncovering) or other military/combat coverings (e.g., tank covering). Thecomposites disclosed herein may also be used in shipping and/orpackaging application. For example, the composites may be used forshipping and packaging of metal products that are susceptible tocorrosion.

Composite Properties

The composite can have a variety of properties, including but notlimited to being vapor permeable, substantially water impermeable,corrosion inhibiting, lightweight, drapable, ultraviolet (UV) resistant,or a combination thereof. For instance, composites disclosed herein mayhave one or more of the following non-limiting properties: (1) adequatewater holdout to keep objects dry, (2) enough physical strength towithstand the rigors of outdoor and prolonged use (2 years), includingUV resistance, (3) enough water vapor transport to allow coveredmoisture to escape when the composite is used to protect an object fromcorrosion, (4) a construction that allows it to be cut and sewn intoarticles for enclosing consumer products, (5) acceptable level ofcorrosion protection, and (6) the ability to be manufactured with normalextrusion coating equipment with normal levels of efficiency. Examplesof properties of the composites disclosed herein are illustrated below.

Basis Weight

In some embodiments of the invention, the composite has a basis weightthat balances the drapability/textile-like properties of the compositewith the durability and corosion-inhibiting properties of the composite.In some embodiments of the invention, the composite may have a basisweight of about 45 g/m² or greater (e.g., about 50 g/m² or greater,about 60 g/m² or greater, about 70 g/m² or greater, about 80 g/m² orgreater, about 90 g/m² or greater, about 100 g/m² or greater, about 110g/m² or greater, about 120 g/m² or greater, about 130 g/m² or greater,about 140 g/m² or greater, about 150 g/m² or greater, about 175 g/m² orgreater, about 200 g/m² or greater, about 225 g/m² or greater, or about250 g/m² or greater). In some embodiments of the invention, thecomposite may have a basis weight of about 290 g/m² or less (e.g., about250 g/m² or less, about 225 g/m² or less, about 200 g/m² or less, about175 g/m² or less, about 150 g/m² or less, about 125 g/m² or less, about100 g/m² or less, or about 80 g/m² or less). In some embodiments, thecomposite has a basis weight of from about 45 g/m² to about 290 g/m²(e.g., about 50 g/m² to about 250 g/m², about 70 g/m² to about 225 g/m²,about 90 g/m² to about 200 g/m², about 100 g/m² to about 175 g/m², orabout 105 g/m² to about 150 g/m²). Basis weight is determined herein byASTM D3776 (1996).

Hydrostatic Head

In some embodiments of the invention, the composite may have asufficient hydrostatic head value so as to maintain sufficient waterimpermeability. As used herein, the term “hydrostatic head” refers tothe pressure of a column of water as measured by its height that isrequired to penetrate a given material and is determined according toAATCC 127 (1998), using the Textest FX3000 at 60 mbar/min for a 100 cm²sample. For example, the composite may have a hydrostatic head of about20 cm or greater (e.g., about 25 cm or greater, about 30 cm or greater,about 35 cm or greater, about 40 cm or greater, or about 45 cm orgreater). In some embodiments of the invention, the composite has ahydrostatic head of about 200 cm or less (e.g., about 180 cm or less,about 160 cm or less, about 140 cm or less, about 120 cm or less, orabout 100 cm or less). In some embodiments, the composite has ahydrostatic head of from about 20 cm to about 200 cm (e.g., from about25 cm to about 180 cm, from about 30 cm to about 160 cm, from about 35cm to about 140 cm, from about 40 cm to about 120 cm, or from about 45cm to about 100 cm).

Moisture—Vapor Transmission Rate (MVTR)

In some embodiments of the invention, the composite may have a suitableMVTR to maintain vapor permeability for its intended uses. As usedherein, the MVTR values are measured according to ASTM E96-B (2005) at23° C. and 50% relative humidity (RH). For example, the composite mayhave an MVTR of about 25 g/m²/day or greater (e.g., about 50 g/m²/day orgreater, about 75 g/m²/day or greater, about 100 g/m²/day or greater,about 125 g/m²/day or greater, about 150 g/m²/day or greater, about 175g/m²/day or greater, or about 200 g/m²/day or greater). In someembodiments, the composite can have an MVTR of about 1000 g/m²/day orless (e.g., about 900 g/m²/day or less, about 800 g/m²/day or less,about 700 g/²/day or less, about 650 g/m²/day or less, about 600g/m²/day or less, about 550 g/m²/day or less, about 500 g/m²/day orless, about 450 g/m²/day or less, about 400 g/m²/day or less, or about350 g/m²/day or less) when measured at 23° C. and 50 RH %. For instance,the composite can have a MVTR of from about 25 g/m²/day and about 1000g/m²/day (e.g., from about 50 g/m²/day and about 500 g/m²/day). Lowerfilm weights, for instance, can produce higher MVTR values.

Accelerated Environmental Exposure (OUV)

In certain preferred embodiments of the invention, the composite will beresistant to ultraviolet radiation, The composite's resistance toultraviolet radiation is shown by QUV testing via ASTM G154-12a after576 hours of exposure. The QIN test chamber used to evaluate ultravioletradiation resistance of materials, may also be used to determine howwell fabric composites can prevent and inhibit the formation of rust orcorrosion on standard steel test plates,

Grab Tensile Strength

In some embodiments of the invention, the composite has a sufficienttensile strength in the machine direction and/or the cross-machinedirection for the desired application. The grab tensile strength isdetermined by measuring the tensile force required to rupture a sampleof a sheet material. The tensile strength mentioned herein is measuredaccording to ASTM D5034 (1995) and is reported in pounds force. In someembodiments of the invention, the composite may have an initial tensilestrength (prior to environmental or QUV exposure) of at least about 80pounds force and/or at most about 150 pounds force in the machinedirection. In some embodiments of the invention, the composite may havean initial tensile strength of at least about 60 pounds force and/or atmost about 100 pounds force in the cross-machine direction. In someembodiments of the invention, the composite can have an grab tensilestrength in the machine and/or cross-machine direction after QUVexposure of 576 hours of at least about 75% of the value prior to QUVexposure (e.g., at least about 80% or at least about 85%).

Elongation

In some embodiments of the invention, the composite has a sufficientelongation in the machine direction and/or the cross-machine direction,Elongation is a measure of the amount that a sample of a sheet materialwill stretch under tension before the sheet breaks, and is measuredaccording to ASTM D5034 (1995). The term “elongation” used herein refersto the difference between the length just prior to breaking and theoriginal sample length, and is expressed as a percentage of the originalsample length. For example, the composite may have an initial elongation(prior to environmental or QUV exposure) of at least about 110% and/orat most about 150% in the machine direction. For example, the compositecan have an initial elongation of at least about 120% and/or at mostabout 200% in the cross-machine direction. In some embodiments of theinvention, the composite may have an elongation in the machine and/orcross-machine direction after QUV exposure of 576 hours of at leastabout 40% of the value prior to QUV exposure (e.g., at least about 50%or at least about 60%).

Ball Burst

In some embodiments of the invention, the composite has a sufficientball bursting strength for the intended material. Ball burst strength isa determination of the force required to rupture textile fabric byforcing a steel ball through the fabric and is measured according toASTM D3787 (2011). In some embodiments of the invention, the compositemay have a ball burst strength of about 50 pounds force or greater. Insome embodiments of the invention, the composite may have a ball burststrength of about 70 pounds force or less.

Trapezoidal Tear Strength

In some embodiments of the invention, the composite has a trapezoidaltear strength in the machine direction and cross-machine direction forthe intended material. Trapezoidal tear strength is a measure of thetearing strength of a nonwoven fabric by the trapezoid procedure using arecording constant-rate-of-extension (CRE) tensile testing machine andis measured according to ASTM D5733 (1995). In some embodiments of theinvention, the composite may have an initial trapezoidal tear strength(prior to environmental or QUV exposure) of about 18 pounds force orgreater and an initial trapezoidal tear strength of about 35 poundsforce or less, in the machine direction. In some embodiments of theinvention, the composite may have an initial trapezoidal tear strength(prior to environmental or QUV exposure) of about 20 pounds force orgreater and an initial trapezoidal tear strength of about 40 poundsforce or less, in the cross-machine direction. In some embodiments ofthe invention, the composite may have a trapezoidal tear strength in themachine and/or cross-machine direction after QUV exposure of 576 hoursof at least about 25% of the value prior to QUV exposure (e.g., at leastabout 30% or at least about 35%)

Corrision Inhibition Testing (Jar Test)

In preferred embodiments of the invention, the composites disclosedherein are corrosion inhibiting, as determined by the Jar Test. The JarTest can determine the corrosion inhibition of a polymer treated with acorrosion inhibitor. The Jar Test can also be used to determine theeffect of the corrosion inhibitor in the polymer on soft metals such assteel, aluminum, and copper. The procedure for conducting the Jar Testis below.

First, n panels of the appropriate metal are prepared, wherein n is thenumber of panels tested (e.g., n=3). For steel panels, the panels shouldbe wiped with DI water using a paper towel, and then dried with a papertowel. For aluminum panels, the test panel should be sanded on bothsides, and then rinsed with isopropyl alcohol and allowed to air dry.For copper panels, the panel should be cleaned to remove any materialfrom the surface, and then rinsed with isopropyl alcohol and allowed todry.

Next, a sample of the polymer of roughly the same size as the test panelis attached to one side of the panel by magnets. A magnet is placedbetween the panel and the polymer so that the two are not in contactwith one another. At least one blank needs to be included for each metaltype being tested. The blank should use a polymer without a corrosioninhibitor present. The panel with the polymer attached is then suspendedin the test chamber and allowed to age for 24 hours. After the 24 houraging period, 20 milliliters of DI water is added and the test chamberis resealed and allowed to equilibrate for 2 hours. After theequilibration period, the test chamber is placed into a water bath setat 50° C. for two hours.

The test panels should be marked so that the sides with the polymerattached can be compared, and the sides opposite the polymer can becompared. If the control panels do not show significant rust on the sideopposite the polymer, the test should be rerun.

Corrosion Optical Density

Corrosion optical density, or optical density of corrosion on a panelmay be determined by opening a panel image in Photoshop; selecting acolor range in the color spectrum of the corrosion (for example, RGBvalues of about 126-105-55); creating a new layer via copy; convertingthe new layer to greyscale with color presets of red 40, yellow 60,green 40, cyan 60, blues 20, and magenta 80; and using the histogram toidentify the mean color density of the panel to estimate the opticaldensity of corrosion on the panel. A lower optical density isrepresentative of a greater extent of corrosion while a relativelyhigher optical density is representative of a lesser extent ofcorrosion.

EXAMPLES Example 1

A composite comprising two nonwoven layers and one intermediate polymerfilm layer was prepared. The first nonwoven layer was a 60 g/m²polypropylene spunbond nonwoven with high ultraviolet (UV) resistanceextrusion laminated together with a 38 g/m² film layer that was appliedat a temperature of 204° C. The film included 88 wt % virgin VISTAMAXX™6202FL, 12 wt % of STANDRIGE COLOR CORPORATION'S SAM81720 (whichcomprises 15 wt % volatile corrosion inhibitor masterbatch from PCCCHEMAX's CHEMSTATO CI-1020 and 85 wt % virgin VISTAMAXX™ 6202FL). Asecond nonwoven layer was applied to the film layer while it was stillmolten and was a 25 g/m² polypropylene spunbond nonwoven treated with ahydrophilic spin finish. The second nonwoven layer was applied with thehydrophilic finish applied opposite the film layer.

Example 2

A composite was prepared in the same manner as Example 1 with the firstnonwoven being a 60 g/m² polypropylene hydrophobic highly ultraviolet(UV) stabilized spunbond nonwoven, the film being a 40 g/m² film layerand the second nonwoven being a 25 g/m² polypropylene spunbond nonwoven.The film layer was formed from 90% of a low-density polyethylene (havinga melt index of 200) and 10% of a volatile corrosion inhibitormasterbatch. The volatile corrosion inhibitor masterbatch contained 15wt % of CHEMSTAT CI-1020, which is a composition of amines and silica,with morpholine as the primary active ingredient, and 85 wt % ofVISTAMAXX™ 6202, a propylene-based elastomer.

Example 3

Three samples were prepared using a 60 gsm PPSB (polypropylenespunbond), dark gray nonwoven as the first nonwoven and a 30 gsm PPSB,light green nonwoven with a hydrophilic finish applied as the secondnonwoven. The film was applied at about 235° C. The VCI masterbatch usedwas Standridge SAM 81720 with VISTAMAXX™ 6202 used as the remainingpolymer. The composite varied as shown below.

Sample A: 30 gsm film with 4 wt % VCI masterbatch.

Sample 30 gsm film with 8 wt % VCI masterbatch.

Sample C: 20 gsm film with 8 wt % VCI masterbatch.

The basis weight and MVTR of the samples were determined and the resultsare provided in Table 1.

TABLE 1 Sample Basis Weight (g/m²) MVTR (g/m²/24 hours) A 126.87 467.74B 128.68 447.32 C 121.49 584.20The lighter weight film provided a higher MVTR value than the twoheavier films.

The corrosion-inhibiting effectiveness of the samples was then tested inaccordance with the Jar Test described above. For each sample, threecorrosion panel weights (g) were tested, and the corrosion level waslisted (e.g., none, slight, medium, heavy).

The results of the Jar Test showing the corrosion for the three testpanels of Sample A are below in Table 2, and depicted in FIG. 4.

TABLE 2 Sample A Corrosion Test Panel Weight (g) Corrosion Level n10.550 Heavy n2 0.513 Heavy n3 0.537 Slight

The results of the Jar Test for the three test panels of Sample B arebelow in Table 3, and depicted in FIG. 5.

TABLE 3 Sample B Corrosion Test Panel Weight (g) Corrosion Level n10.570 Slight n2 0.573 Heavy n3 0.567 Slight

The results of the Jar Test for the three test panels of Sample C arebelow in Table 4, and depicted in FIG. 6.

TABLE 4 Sample C Corrosion Test Panel Weight (g) Corrosion Level n10.528 Slight n2 0.527 None n3 0.534 Slight

The example demonstrated that higher breathability results from usinghigher extrusion temperatures, as well as producing a composite withgood corrosion protection. These results are confirmed by the corrosionoptical densities of these samples shown in Table 5.

TABLE 5 Corrosion Optical Density Sample A Sample B Sample C FIG. 4 FIG.5 FIG. 6 n1 118 113 114 n2 141 135 136 n3 172 138 165 Average 140 128136

Example 4

Five samples were prepared using an 80 gsm PPSB (polypropylenespunbond), dark gray nonwoven as the first nonwoven and a 30 gsm PPSB,light green nonwoven with a hydrophilic finish applied as the secondnonwoven. The film was applied at about 220° C. The VCI masterbatch usedwas Standridge SAM 81720 with VISTAMAXX™ 6202 used as the remainingpolymer. The composite varied as shown below.

Sample D: 40 gsm film with 10 wt % masterbatch,

Sample E: 40 gsm film with 12 wt % VCI masterbatch.

Sample F: 50 gsm film with 12 wt % VCI masterbatch.

Sample G: 60 gsm film with 12 wt % VCI masterbatch.

Sample H: 40 gsm film with 14 wt % VCI masterbatch.

The samples were tested to assess the performance of composites havingvarious corrosion-inhibiting masterbatch amounts. The basis weight andMVTR of the samples were determined. The results are in Table 6.

TABLE 6 Sample Basis Weight (g/m²) MVTR (g/24 hours) D 149.88 — E 161.40119.99 F 166.09 114.83 G 176.14 113.36 H 157.32 —

As shown in this example, increasing the film weights of VCI, at leastwith this recipe, did not show an appreciable change in MVTR. However,the use of a heavier first nonwoven, 80 gsm versus 60 gsm as used inExample 3, does show how the total sample weight can impact MVTR.

The results of the Jar Test showing the corrosion for the three testpanels of Sample D are below in Table 7.

TABLE 7 Sample D Corrosion Test Panel Weight (g) Corrosion Level n10.639 Slight n2 0.708 Slight n3 0.663 None Average: 0.670 N/A

The results of the Jar Test showing the corrosion for the three testpanels of Sample E are below in Table 8.

TABLE 8 Sample E Corrosion Test Panel Weight (g) Corrosion Level n10.650 None n2 0.649 Medium n3 0.652 None Average: 0.650 N/A

The three test panels for Sample F were not subjected to a Jar Test.

The results of the Jar Test showing the corrosion for the three testpanels of Sample G are below in Table 9.

TABLE 9 Sample G Corrosion Test Panel Weight (g) Corrosion Level n10.674 Slight n2 0.723 None n3 0.724 None Average: 0.707 N/A

The results of the Jar Test showing the corrosion for the three testpanels of Sample are below in Table 10.

TABLE 10 Sample H Corrosion Test Panel Weight (g) Corrosion Level n10.628 None n2 0.660 Slight n3 0.655 None Average: 0.648 N/A

This example was designed to investigate the processability of producinga film with higher and higher levels of VCI masterbatch. The corrosionprotection was good at all additive levels and film weights; however,the sample using 14 wt % masterbatch (Sample H) began to lose integrity.

TABLE 11 Property Tested Value Basis Weight 123 g/m² Hydrostatic Head27.66 cm MVTR 190.89 g/24 hours Grab Tensile Strength-Break (MD¹) 88.90lbf Grab Tensile Strength-Elongation (MD) 135.56% Grab TensileStrength-Break (XD²) 72.31 lbf Grab Tensile Strength-Elongation (XD)151.72% Trapezoid Tear Strength-Maximum Break (MD) 23.69 lbf TrapezoidTear Strength-Maximum Break (XD) 27.77 lbf Ball Bursting Strength 59.12lbf ¹Machine Direction ²Cross-Machine Direction

Example 5

A sample (Sample I) was prepared in the same manner as Example 1 exceptthat the film was 40 gsm instead of 38 gsm and was extruded at 218° C.Various properties of the sample were tested, including basis weight,hydrostatic head, moisture-vapor transmission rate, grab tensilestrength, trapezoidal tear strength, and ball burst strength. Theresults of those tests are shown in Table 11. The results of the JarTest showing the corrosion for the three test panels of Sample I arebelow in Table 12, and depicted in FIG. 7.

TABLE 12 Sample I Corrosion Test Panel Weight (g) Corrosion Level n10.512 Moderate n2 0.473 Moderate n3 0.509 Moderate Average: 0.498 N/A

Example 6

A sample (Sample J) was prepared in the same manner as Example 5 exceptthat it was extruded at 208° C. Various properties of the sample werethen tested, including hydrostatic head, moisture-vapor transmissionrate, and corrosion inhibition (Jar Test). The results of those testsare in Tables 13-15 below for the 3 test panels. Table 13 provides themoisture-vapor transmission rate of Sample J.

TABLE 13 Property Tested Value MVTR 53.8 g/m²/24 hours

The reduction in extrusion temperature between Example 5 and Example 6corresponds to the changes in hydrostatic head and MVTR values,Generally, the higher the extrusion temperature, the lower thehydrostatic head but the higher the MVTR.

Table 14 provides the hydrostatic head of Sample J, at 60 g/m2 side tocolumn.

TABLE 14 After 288 After 288 After 576 Initial Initial hours hours hoursAfter 576 N (mbar) (cm) (mbar) (cm) (mbar) hours (cm) 1 93.5 95.4 87.589.3 61.5³ 62.7 2 108.0 110.2 103.0³ 105.1 69.5³ 70.9 3 143.0³ 145.969.0³ 70.4 48.0³ 49.0 Average 114.8 117.1 86.5 88.2 59.7 60.9 ³Sampleleaked between layers

The results of the Jar Test showing the corrosion for the three testpanels of Sample J are below in Table 15, and depicted in FIG. 8.

TABLE 15 Sample J Corrosion Level n1 Slight n2 Slight n3 Slight

The comparative corrosion optical densities for the test panels ofSample I and Sample J are provided in Table 16.

TABLE 16 Corrosion Optical Density Sample I Sample J FIG. 7 FIG. 8 n1132 96 n2 151 96 n3 185 95 Average 156 96

Example 7

One sample (Sample K) was prepared in the same manner as Example 1,except that a 40 g/m² film layer was applied at a melt temperature below200° C., the film including 88% 200 MI LDPE (low density polyethylene)and 12% of SAM81720. Sample K was tested for grab tensile strength(initial and QUV exposure 576 hours , trapezoidal tear strength (initialand QUV exposure 576 hours), and ball bursting strength. The results ofthose tests are shown in Tables 15-21 for 5 test panels. Table 17 showsinitial grab tensile strength for the machine direction tests for SampleK.

TABLE 17 Initial Grab Tensile Initial Grab Tensile Strength-Max LoadStrength-Elongation at Break (lbf) at Break (%) Sample K (MachineDirection) (Machine Direction) n1 97.52 140.95 n2 91.39 122.41 n3 102.07159.08 n4 94.52 132.95 n5 100.70 144.15 Average: 97.24 139.91 Maximum:102.07 159.08 Minimum: 91.39 122.41 Standard 4.39 13.61 Deviation:

TABLE 18 QUV (576 Hours) QUV (576 Hours) Grab Tensile Strength- GrabTensile Strength- Max Load at Break (lbf) Elongation at Break (%) SampleK (Machine Direction) (Machine Direction) n1 85.34 67.48 n2 89.34 85.48n3 82.06 69.08 n4 81.12 71.08 n5 74.29 52.44 Average: 82.43 69.11Maximum: 89.34 85.48 Minimum: 74.29 52.44 Standard 5.58 11.75 Deviation:

Table 18 shows QUV grab tensile strength at 576 hours for the machinedirection tests for Sample K. Table 19 shows initial grab tensilestrength for the cross-machine direction tests for Sample K.

TABLE 19 Initial Grab Tensile Initial Grab Tensile Strength-Max LoadStrength-Elongation at Break (lbf) at Break (%) Sample K (Cross-MachineDirection) (Cross-Machine Direction) n1 67.64 154.95 n2 70.77 172.01 n368.91 164.68 n4 69.10 160.15 n5 70.08 179.49 Average: 69.30 166.26Maximum: 70.77 179.49 Minimum: 67.64 154.95 Standard 1.20 9.69Deviation:

Table 20 shows QUV grab tensile strength at 576 hours for thecross-machine direction tests for Sample K. Grab Tensile strengthproperties for maximum load at break changed 15.23% in the machinedirection and 23% in the cross-machine direction from initial to QUV at576 hours. Elongation changed at 50% in both the machine direction andcross-machine direction.

TABLE 20 QUV (576 Hours) QUV (576 Hours) Grab Tensile Strength- GrabTensile Strength- Max Load at Break (lbf) Elongation at Break (%) SampleK (Cross-Machine Direction) (Cross-Machine Direction) n1 51.74 82.95 n244.21 60.81 n3 57.90 90.95 n4 53.42 92.15 n5 59.69 97.88 Average: 53.3984.95 Maximum: 59.69 97.88 Minimum: 44.21 60.81 Standard 6.06 14.51Deviation:

Table 21 shows the initial trapezoidal tear strength test results forthe machine direction and cross-machine direction for Sample K. Table 22shows the QUV (at 576 hours) trapezoidal tear strength test results forthe machine direction and cross-machine direction for Sample TrapezoidTear strength in the initial analysis averaged 27.04 lbf in the machinedirection and 30.93 lbf in the cross-machine direction. Trapezoidal tearstrength maximum load for the 576 hour weathered sample decreased 44.9%in the machine direction and 73.5% in the cross-machine direction fromthe initial sample.

TABLE 21 Initial Trapezoidal Initial Trapezoidal Tear Strength-Max TearStrength-Max Load at Break (lbf) Load at Break (lbf) Sample K (MachineDirection) (Cross-Machine Direction) n1 30.24 35.60 n2 22.42 29.44 n328.42 23.88 n4 28.02 33.32 n5 26.10 32.41 Average: 27.04 30.93 Maximum:30.24 35.60 Minimum: 22.42 23.88 Standard 2.97 4.52 Deviation:

TABLE 22 QUV (576 hours) QUV (576 hours) Trapezoidal Tear Strength-Trapezoidal Tear Strength- Max Load at Break (lbf) Max Load at Break(lbf) Sample K (Machine Direction) (Cross-Machine Direction) n1 10.378.02 n2 8.19 5.88 n3 4.64 7.39 n4 10.04 10.14 n5 6.29 9.58 Average: 7.918.20 Maximum: 10.37 10.14 Minimum: 4.64 5.88 Standard 2.45 1.71Deviation:

Table 23 shows ball burst strength test results for Sample K. Ball burststrength had a maximum load break average of 57.95 lbf.

TABLE 23 Ball Burst Strength- Sample K Max Peak Load (lbf) n1 53.43 n262.64 n3 53.35 n4 64.73 n5 55.59 Average: 57.95 Maximum: 64.73 Minimum:53.35 Standard 5.37 Deviation:

The results confirmed that the physical properties of the compositecontinues to show very good results, before and after UV testing, evenwith a film recipe using LDPE instead of the VISTAMAXX™ 6202 whenproduced at commercial line speeds.

Example 8

Two samples Samples L and M) were prepared in the same manner as Example7. Various properties of the samples were tested, including basisweight, hydrostatic head, moisture-vapor transmission rate, and ballbursting strength. The results of those tests are shown in Table 24.

TABLE 24 Property Tested Sample L Sample M Basis Weight (osy) 128.9 gsm127.5 gsm Hydrostatic Head (cm) 69.1 78.7 MVTR (g/m²/24 hours) 348.6100.5 Ball Bursting Strength (lbf) 56.19 54.21

The results confirm good hydrostatic head and ball burst results as wellas adequate MVTR using 200 MI LDPE.

The results of the Jar Test showing the corrosion for the three testpanels of Sample L are below in Table 25, and depicted in FIG. 9.

TABLE 25 Sample L Corrosion Level n1 Slight n2 Slight n3 Slight

The results of the Jar Test showing the corrosion for the three testpanels of Sample M are below in Table 26, and depicted in FIG. 10.

TABLE 26 Sample M Corrosion Level n1 Slight n2 None n3 Moderate

The comparative corrosion optical densities for the test panels ofSample L and Sample M are provided in Table 27.

TABLE 27 Corrosion Optical Density Sample L Sample M FIG. 9 FIG. 10 n1108 75 n2 94 69 n3 100 71 Average 101 72

Samples were similar in unit weight, hydrostatic head and ball burststrength. The MVTR of the samples varied, likely because of thevariability of film thickness, variability of the distribution of theVCI compound, and the use of a small sample size.

Example 9

One sample (Sample N) was prepared in the same manner as Example 1,except the sample used a 20 g/m² film layer that was applied at atemperature of 255° C. and the second nonwoven had a basis weight 30g/m². The film included 9 wt % VCI masterbatch produced by PhoenixPlastics, item #720N (this masterbatch used 15 wt % PCC CFLEMAX'sCHEMSTAT® CI-1020 and 85 wt % IDPE), 46 wt % Dow 722 and 45 wt %VISTAMAXX™ 6202 FL.

Various properties of the sample were then tested, including basisweight, hydrostatic head, moisture-vapor transmission rate, grab tensilestrength, QUV accelerated weathering testing, trapezoidal tear strength,and ball bursting strength. The results are shown in Table 28.

TABLE 28 Property Tested Value Basis Weight 115.3 gsm Hydrostatic Head61 cm MVTR 224.5 g/m²/24 hours Initial Grab Tensile Strength-Break (MD¹)90.4 lbf Initial Grab Tensile Strength-Elongation (MD) 129.7% InitialGrab Tensile Strength-Break (XD²) 66.2 lbf Initial Grab TensileStrength-Elongation (XD) 155.8% QUV (576 hours) Grab Tensile Strength-65.6 lbf Break (MD) QUV (576 hours) Grab Tensile Strength-  73.5%Elongation (MD) QUV (576 hours) Grab Tensile Strength- 43.7 lbf Break(XD) QUV (576 hours) Grab Tensile Strength-  80.1% Elongation (XD)Initial Trapezoid Tear Strength-Maximum Break 27.1 lbf (MD) InitialTrapezoid Tear Strength-Maximum Break 32.5 lbf (XD) QUV (576 hours)Trapezoid Tear Strength- 12.1 lbf Maximum Break (MD) QUV (576 hours)Trapezoid Tear Strength- 18.8 lbf Maximum Break (XD) Ball BurstingStrength 57.3 lbf ¹Machine Direction ²Cross-Machine Direction

Example 10

The purpose of the tests of this example is to evaluate ultravioletradiation resistance of materials and to determine how well fabriccomposites can prevent and inhibit the formation of rust or corrosion onstandard steel plates. The fabric test samples are prepared by creatinga pocket or sleeve sized to hold the steel test plate. The fabric issonically seamed on three sides to ensure a watertight seal long thoseedges. The dimensions of the pocket are approximately 3 inches wide byapproximately 4 inches long. One of the short edges is left open and thesteel plate is inserted through this opening. The pocket is trimmed to ¼inch below the bottom plate. The sonic seams are approximately ¼ inchwide. The plates are approximately 2 inches wide and 3 ½ inches long.

The ultraviolet light test is set up according to ASTM method G152,cycle 44, which includes (i) exposure to light for 8 hours at 70° C.,(ii) subjecting the sample to four hours of darkness under conditions toproduce condensation (100% relative humidity at 50° C.), and (iii)irradiating the sample at 1.55 W/m² of ultraviolet radiation. Thesamples are positioned in the chamber such that the unsealed bottom edgeof the samples may receive moisture vapor in the chamber Samples areevaluated visually for corrosion at intervals of 144, 288 and 576 hours.The fabric surrounding the plates is evaluated visually at 576 hours forsigns of degradation.

Three samples (collectively Sample O) was prepared as described above.The samples were tested according to QUV accelerated weathering andcompared to control samples at 144 hours, 288 hours, and 576 hours. FIG.11 shows the control plates after 144 hours and highly corroded. FIG. 12shows Sample O plates at 144 hours and are substantially free ofcorrosion. FIG. 13 shows the control plates after 288 hours and is alsohighly corroded. FIG. 14 shows Sample O plates at 288 hours and aresubstantially free of corrosion. FIG. 15 shows the control plates after576 hours and it is again highly corroded. FIG. 16 shows Sample O platesat 576 hours and are substantially free of corrosion. Table 29 shows theresults of the optical corrosion optical densities measured for theplate samples of this Example 10.

TABLE 29 Corrosion Optical Density 144 hours 288 hours 576 hours controlSample O control Sample O control Sample O FIG. 11 FIG. 12 FIG. 13 FIG.14 FIG. 15 FIG. 16 n1 117 158 119 165 111 132 n2 114 151 121 170 110 142n3 109 142 124 171 112 146 Average 113 150 121 168 111 140

According to the data in Table 29, the extent of corrosion as measuredby the optical corrosion optical density may be reduced by more than 26%over the course of 576 hours.

FIG. 17 shows the control fabric for three samples after 576 hours andit is apparent that corrosion from the test samples is present on thefabric samples. FIG. 18 shows the fabric for three samples of Sample Oat 576 hours and there is no visible corrosion from in these testsamples,

As apparent in FIGS. 11-18, the corrosion inhibitor appears to haveeffectively, efficiently, and rapidly sublimed out of the cover fabricand bonded effectively to the metal surface. The corrosion protectionvisible at the minimum of 144 hours in FIGS. 11 and 12. suggests a rapidbuildup of corrosion-inhibiting vapor within a corrosion protectingenvironment formed between the metal surface and composite. Based onthese tests, it is believed that corrosion inhibition can be achievedquickly upon placing a finished end product composite over any metalproduct. The corrosion protection lasts through 576 hours of chamberexposure. This is the length of time used for durability testing ofsimilar covers currently used for protective covers.

The control fabrics in FIG. 17 show significant fading and beginning ofdegradation. At 576 hours, the control fabrics would be expected to beshowing this type of degradation. The fabrics of Sample O shown in FIG.18 appear to exceed the control fabric in both fading resistance andresistance to degradation.

Example 11

Eight samples were prepared in the same manner as Example 1 except withthe following film compositions and weights using 88 wt % of the virginpolymer and 12 wt % of a VCI masterbatch (the masterbatch including 85wt % of the virgin polymer and 15 wt % of the VCI). The virgin polymersand the film weights are provided below.

Sample S: VISTAMAXX™ 6202, 20 gsm film

Sample T: VISTAMAXX™ 6202, 24 gsm film

Sample U: VISTAMAXX™ 6202, 27 gsm film

Sample V: LOPE, 20 gsm film

Sample W: LDPE, 24 gsm film

Sample X: LDPE, 27 gsm film

The samples were then tested for corrosion inhabitance (Jar Testdescribed herein, but with a rank of 1 (high corrosion), 2 (moderatecorrosion), and 3 (low corrosion)), MVTR, and hydrostatic head (usingTextest FX3000 with a gradient of 10 mbar/min). The results are shown inTable 30.

TABLE 30 Sample MVTR (g/m²/24 hrs) Hydrohead (cm) Corrosion Level S339.5 50.4 2 T 153.1 60.3 2 U 164.5 56.3 2 V 641.0 48.5 1 W 305.0 58.1 3X 222.7 58.0 3The use of an LDPE based VCI masterbatch did not negatively affecthydrohead and appears to positively effect MVTR, The tests show a clearrelationship of MVTR to film weight with lower film weights resulting inhigher MVTP's. Although the corrosion results seem inconclusive, therewas adequate protection with the thinner films.

The compositions and methods of the appended claims are not limited inscope by the specific compositions and methods described herein, whichare intended as illustrations of a few aspects of the claims and anycompositions and methods that are functionally equivalent are intendedto fall within the scope of the claims. Various modifications of thecompositions and methods in addition to those shown and described hereinare intended to fall within the scope of the appended claims. Further,while only certain representative compositions and method stepsdisclosed herein are specifically described, other combinations of thecompositions and method steps also are intended to fall within the scopeof the appended claims, even if not specifically recited. Thus, acombination of steps, elements, components, or constituents may beexplicitly mentioned herein or less, however, other combinations ofsteps, elements, components, and constituents are included, even thoughnot explicitly stated. When numerical ranges of varying scope are setforth herein, it is contemplated that any combination of these valuesinclusive of the recited values can be used. Further, ranges can beexpressed herein as from “about” one particular value, and/or to “about”another particular value, When such a range is expressed, another aspectincludes from the one particular value and/or to the other particularvalue. Similarly, when values are expressed as approximations, by use ofthe antecedent “about,” it will be understood that the particular valueforms another aspect. It will be further understood that the endpointsof each of the ranges are significant both in relation to the otherendpoint, and independently of the other endpoint. Unless statedotherwise, the term “about” means within 5% (e.g., within 2% or 1%) ofthe particular value modified by the term “about.” The term “comprising”and variations thereof as used herein is used synonymously with the term“including” and variations thereof and are open, non-limiting terms.Although the terms “comprising” and “including” have been used herein todescribe various embodiments, the terms “consisting essentially of” and“consisting of” can be used in place of “comprising” and “including” toprovide for more specific embodiments and are also disclosed.

What is claimed is:
 1. A composite comprising: a first layer comprising a first nonwoven; and a second layer adjacent to and mechanically integrated with the first layer, the second layer comprising: a polymer having a melt flow index of about 10 g/10 mins to about 200 g/10 mins, and a corrosion inhibitor, wherein the composite has a moisture vapor transmission rate of from about 25 g/²/day to about 1000 g/m²/day when measured at about 23° C. and about 50 RH%.
 2. The composite of claim 1, further comprising a third layer adjacent to and mechanically integrated with the second layer, wherein the third layer comprises a second nonwoven. The composite of claim 1, wherein the second layer is melt bonded to the first layer.
 4. The composite of claim 1, wherein one or more of the first nonwoven and the second nonwoven includes a spunbond layer.
 5. The composite of claim 1, wherein the polymer is present in the second layer in an amount of at least about 50% to about 99%, by weight of the second layer.
 6. The composite of claim 1, wherein the corrosion inhibitor is present in an amount of about 0.5% to about 3%, by weight of the second layer.
 7. The composite of claim 1, wherein the corrosion inhibitor comprises morpholine.
 8. The composite of claim 1, wherein the second layer further comprises a carrier for the corrosion inhibitor.
 9. The composite of claim 8, wherein the carrier for the corrosion inhibitor comprises silica.
 10. The composite of claim 1, wherein the composite has a hydrostatic head of from about 20 cm to about 200 cm.
 11. A protective cover comprising the composite of claim
 1. 12. A method of producing a composite, the method comprising extruding a corrosion-inhibiting mixture comprising a polymer having a melt flow index of about 10 g/10 mins to about 200 g/10 mins and a corrosion inhibitor onto a surface of a first nonwoven at an extrusion temperature of from about 170° C. to about 320° C. to form a film layer on the first nonwoven.
 13. The method of claim 12, further comprising the step of mixing the polymer with a corrosion inhibitor to produce the corrosion-inhibiting mixture.
 14. The method of claim 12, further comprising the step of applying a second nonwoven to the film layer of the first nonwoven.
 15. The method of claim 14, wherein the second nonwoven is added to the film layer while the film layer is molten.
 16. The method of claim 14, further comprising treating a surface of one or more of the first nonwoven and second nonwoven, independently, with a hydrophilic coating or a hydrophobic coating.
 17. The method of claim 12, wherein the polymer in the film layer comprises a propylene-ethylene copolymer.
 18. The method of claim 12, wherein the corrosion inhibitor is present in an amount of about 0.5% to about 3%, by weight of the corrosion-inhibiting mixture.
 19. The method of claim 12, wherein the corrosion inhibitor comprises morphohne. A composite produced by a method comprising extruding a corrosion-inhibiting mixture comprising a polymer having a melt flow index of about 10 g/10 mins to about 200 g/10 mins and a corrosion inhibitor onto a surface of a first nonwoven at an extrusion temperature of from about 170° C. to about 320° C. to form a film layer on the first nonwoven. 